Transport assembly

ABSTRACT

Provided is a transport assembly for use in the transport of a large heavy load, including a frame unit realized to lie on a load platform of a transport vehicle; a number of first load-positioning beams, wherein a first load-positioning beam is realized to span a single frame unit; and/or a number of second load-positioning beams, wherein a second load-positioning beam is realized to span a pair of adjacent frame units; and a part adapter realized to engage with a load-positioning beam and to engage with the load. The embodiments further describe a method of securing a large heavy load on a load platform during a transport maneuver.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. application Ser.No. 16/347,878, filed May 7, 2019, and entitled “TRANSPORT ASSEMBLY”,which claims priority to PCT Application No. PCT/EP2017/076684, having afiling date of Oct. 19, 2017, which is based on German Application No.10 2016 222 212.0, having a filing date of Nov. 11, 2016, the entirecontents all of which are hereby incorporated by reference.

FIELD OF TECHNOLOGY

The following relates to a transport assembly for securing a large heavyload to a load platform during a transport maneuver. The followingfurther describes a method of securing a large heavy load on a loadplatform during a transport maneuver.

BACKGROUND

During the manufacture of a large structure such as a wind turbine it isoften necessary to transfer one or more components from one location toanother. The installation of a large machine such as a wind turbine alsooften requires the transfer of one or more components between locations.

Such load transfer maneuvers can become expensive when it is necessaryto move loads that have irregular shapes in addition to being veryheavy. For example, the different parts of a wind turbine can havedifferent shapes and different weights. A nacelle unit of a large 10-20MW generator can weigh in the region of several hundred metric tons, forexample. Its transport is made difficult owing to its irregular shapeand to the lack of external features which could be used to hold itduring transport. Transport of such an irregular heavy object can bemade even more difficult if its center of gravity is offset from itsgeometrical center. It is necessary to ensure that the load and thetransport equipment are not damaged during a transport maneuver.However, an irregularly shaped object may exert bending moments on theloading platform and may damage the transport equipment. A poorly orinadequately supported load may itself be damaged during transport bysuch bending moments.

A further problem arises when it is necessary to handle severaldifferent versions of a product, for example to transport differentversions of a wind turbine component and when each version of acomponent has a different weight and different dimensions.

For these reasons, it is generally necessary to design and constructpurpose-built and specially designed transport equipment for eachdifferent type of load. However, purpose-built or custom equipment haslimited re-usability and adds significantly to the overall manufacturingor installation costs.

SUMMARY

An aspect relates to a more economical way of transporting largeirregular loads.

According to embodiments of the invention, the transport assembly isintended for use in the transport of a large heavy load, and comprises aframe unit realized to fit over a load platform of a transport vehicle;one or more first load-positioning beams, each realized to span a singleframe unit and/or one or more second load-positioning beams, eachrealized to span a pair of adjacent frame units; and at least one partadapter realized to engage with a load-positioning beam and to engagewith the load.

An advantage of the transport assembly according to embodiments of theinvention is that it allows a very heavy load to be securely held inplace on a load platform of a transport vehicle in such a way that theload is evenly distributed over the load platform. Furthermore, themodular nature of the transport assembly allows various different kindsof load—with different dimensions and different weights—to betransported using the same transport assembly. In other words, assemblyconfiguration of the inventive transport assembly can easily be adjustedfor the transport of one kind of load, and then later adjusted again forthe transport of a different load. Even for loads with irregular shapes,the transport assembly allows a balanced and even load distribution. Theinventive transport assembly effectively prevents bending moments thatwould otherwise place stress on the transport equipment.

According to embodiments of the invention, the method of securing alarge heavy load on a load platform during a transport maneuvercomprises the steps of arranging a single frame unit of such a transportassembly over the load platform and then arranging at least one firstload-positioning beam across the single frame unit; or arranging twoframe units of such a transport assembly over a pair of adjacent loadplatforms, and arranging at least one second load-positioning beamacross the frame units. In a subsequent step, a part adapter of thetransport assembly is engaged with a load-positioning beam, and the loadis engaged with the part adapter.

The inventive method is favorably quick and economical to carry out,since it is not necessary to provide dedicated load-carrying means fordifferent kinds of load.

Particularly advantageous embodiments and features of embodiments of theinvention are given by the dependent claims, as revealed in thefollowing description. Features of different claim categories may becombined as appropriate to give further embodiments not describedherein.

In the following, it may be assumed that the load to be transported is awind turbine component such as a nacelle unit, a tower head unit, agenerator unit, etc. Such parts are generally cumbersome and unwieldy,having great weight in addition to a complicated shape, particularlywhen the component is for use in a large wind turbine. Here, the term“large wind turbine” is to be understood to mean a wind turbine with apower output in the region of 10-20 MW as mentioned in the introduction.It may be assumed that the transport assembly is realized to transport acomponent such as a nacelle unit with a weight that might exceed 1000metric tons.

The frame unit is shaped to fit essentially exactly over the loadingplatform that will be used in the transport maneuver. A loading platformmay be understood to be a long flat carrier that can be moved by rollersor wheels. For example, a loading platform with a length of about 25 mand a width of about 3 m can be mounted onto an arrangement of multiplewheel axles. In preferred embodiments of the invention, the frame unitcomprises a pair of parallel supporting beams or lateral beams arrangedto lie on either longitudinal side of the load platform. The two lateralbeams are connected together by means of a plurality of cross-connectingbeams or transverse beams arranged at right angles to the lateral beamsand welded or bolted to the lateral beams in order to fix theirposition. A transverse beam is arranged to rest on an upper surface ofthe load platform to ensure optimal load transfer onto the flatbedsurface of the load platform. In preferred embodiments of the invention,the lateral beams extend along the sides of the load platform so thattheir upper faces essentially lie flush with the upper surface of theload platform, and so that the lower faces of the transverse beams reston the upper surface of the load platform. This arrangement allows afavorably effective load transfer onto the load platform.

The inventive transport assembly can be used with a single load platformbut can equally well be used with two or more load platforms. Inpreferred embodiments of the invention, therefore, the firstload-positioning beam is realized to engage with a part adapterpositioned centrally over a single frame unit on a single load platform,and the second load-positioning beam is realized to engage with a partadapter positioned centrally over a pair of adjacent frame units on twoload platforms, etc. The first load-positioning beam may be referred toin the following as a “short” load-positioning beam, since it only spansone frame unit. The length of the short load-positioning beam need notbe any longer than the width of the frame unit. The secondload-positioning beam may be referred to in the following as a “long”load-positioning beam, since it spans two (or more) frame units. Thelength of the long load-positioning beam can comprise at least thecombined width of two frame units, for example, to allow for a spacebetween the adjacent load platforms.

A load-positioning beam is secured to the frame unit in some way so thatthe load can be safely held at all times during the transport maneuver.To this end, in preferred embodiments of the invention, the transportassembly comprises a number of holding elements or holders arranged tohold a load-positioning beam in place on the frame unit. In onepreferred embodiment of the invention, a holding element or holder isarranged to extend upward from a lateral beam of the frame unit toengage from below with a load-positioning beam. Equally, a holdingelement or holder can be arranged to extend downward from aload-positioning beam to engage from above with a lateral beam. Forexample, a holding element or holder can comprise a rod or similardevice extending downward from a load-positioning beam and into acorresponding hole in a lateral beam. A row of holes spaced at intervalsin the upper side of each lateral beam can offer a number ofpossibilities in arranging the load-positioning beams. In a similarmanner, a holding element or holder can comprise a rod extending upwardfrom a lateral beam and into a corresponding hole on the under surfaceof a load-positioning beam. Here, a series of rods spaced at intervalsalong the upper side of each lateral beam can offer a number ofpossibilities in arranging the load-positioning beams. In furtherpreferred embodiments of the invention, a holding element or holder isconstructed as a plate comprising a rectangular cut-out to engage abeam. The plate can be bolted to a lateral beam, for example, andarranged so that the cut-out faces upwards, ready to receive aload-positioning beam. In this preferred embodiment, a matchingarrangement of through-holes in a holding plate and in a complementaryarrangement of fins mounted to a load-positioning beam can be providedfor receiving fasteners to secure the load-positioning beam to the frameunit. Of course, these embodiments are exemplary, and other realizationsare possible. In each case, it is preferable that the load-positioningbeams rest on the load platform(s) so that the weight of the load can betransferred evenly to the load platform(s).

The part adapter is also secured to the frame unit in some way so thatthe load can be safely held at all times during the transport maneuver.In preferred embodiments of the invention, therefore, the transportassembly comprising an engaging structure arranged to form a connectionbetween the part adapter and a load-positioning beam, wherein theengaging structure comprises an arrangement of bars mounted to the partadapter and a complementary arrangement of fins mounted to aload-positioning beam, which bars and fins comprise matchingthrough-holes for receiving fasteners. For example, a load-positioningbeam can be equipped with a number of vertical fins extending outwardfrom the beam, and the part adapter can be equipped with one or morecorresponding arrangements of vertical bars or fins. Once the partadapter has been put into place over the frame unit(s), it can besecured to the load-positioning beam(s) by fasteners inserted throughthe matching through-holes.

As mentioned above, the transport assembly is intended for use in thetransport of large and heavy components such as the nacelle unit of alarge wind turbine. In preferred embodiments of the invention,therefore, the part adapter is realized to engage with a circular towerhead interface of a wind turbine. The part adapter is an essentiallycircular element with a diameter in the range of 4-7 m, and shaped tofit inside the tower head interface, or outside the tower headinterface, depending on the manner in which the tower head interface ofthe nacelle unit has been constructed. For example, if the tower headinterface has been constructed with an inner flange which will be boltedto a corresponding flange at the top of a wind turbine tower, the partadapter can be shaped to fit that flange. When the nacelle unit islowered into place on the part adapter, the flange will rest on theupper surface of the part adapter. Of course, the part adapter can alsobe secured to the flange if necessary.

In the case of a large and unwieldy part such as a tower head unit ornacelle unit, it may be that the center of gravity of the load does notlie over the part adapter. Therefore, in preferred embodiments of theinvention, the method comprises a preliminary step of determining anoptimal position of at least one transverse beam relative to the lateralbeams and the load-positioning beams of the frame unit. For example, anacelle unit can be held in place by a part adapter mounted over twoload-positioning beams arranged towards one end of the frame unit. Thecenter of gravity of the nacelle unit may lie outside of the regiondefined by the load-positioning beams and the part adapter and may liefurther behind this region. To counteract the bending moment that wouldotherwise act on the load platform, an additional transverse beam isplaced further behind and secured to the lateral beams. The weight ofthe load can therefore be evenly distributed on the load platformthrough the load-positioning beams and the transverse beams.

BRIEF DESCRIPTION

Some of the embodiments will be described in detail, with references tothe following Figures, wherein like designations denote like members,wherein:

FIG. 1 shows an exemplary embodiment of the inventive transport assembly

FIG. 2A shows a first embodiment of the inventive transport assemblyduring loading;

FIG. 2B shows a first embodiment of the inventive transport assemblyafter loading;

FIG. 3 shows the transport assembly of FIGS. 2A and 2B in use during thetransport of a load;

FIG. 4 shows a first embodiment of the inventive transport assembly;

FIG. 5 shows the transport assembly of FIG. 4 in use during thetransport of a load; and

FIG. 6 shows the transport assembly of FIGS. 2A and 2B in use during thetransport of a load.

In the diagrams, like numbers refer to like objects throughout. Aspectsin the diagrams are not necessarily drawn to scale.

DETAILED DESCRIPTION

FIG. 1 shows an exemplary embodiment of the inventive transport assembly1, with a frame unit 10 constructed to rest on the load platform 3 of atransport vehicle (not shown), two different kinds of load-positioningbeam 131, 132, and a part adapter 14.

The frame 10 essentially comprises a pair of parallel lateral beams 12that will lie on either long side of the load platform 3, and severaltransverse or cross-connector beams 11 held in place by the lateralbeams 12. A number of upright holding plates 16 are arranged on theinner and outer sides of each of the lateral beams 12. These holdingplates 16 are shaped and arranged to accommodate a number ofload-positioning beams 131, 132.

The diagram shows two load-positioning beams 131, 132 with differentlengths. The short load-positioning beam 131 is for use with a singleframe 10 arranged on a single load platform, while the longload-positioning beam 132 is for use with two frames 10 arranged side byside on two adjacent load platforms. Each load-positioning beam 131, 132has a number of fins 133 extending along its vertical side faces. Thesefins 133 will be used to secure the load-positioning beam 131, 132 tothe frame 10, and to secure a part adapter 14 to the load-positioningbeam 131, 132, as will be explained below.

The part adapter 14 in this exemplary embodiment will be used to supporta nacelle unit of a wind turbine during a transport maneuver. The partadapter 14 or “tower barrel” is constructed to have the same dimensionsas the uppermost region of the tower of that wind turbine, so that thetower head interface or yaw ring of that nacelle unit will fit onto orinto the part adapter 14.

FIGS. 2A and 2B show a first arrangement of the inventive transportassembly 1, using the short load-positioning beam 131, frame 10 andadapter 14 of FIG. 1. In this setup, a relatively small nacelle is to betransported, i.e. the weight and dimensions of the nacelle allow it tobe borne on a single load platform of a transport vehicle. On theleft-hand side of the diagram, two short load-positioning beams 131 areshown in place on the frame 10. Each load-positioning beam 131 spans theframe 10 and is held in place by holding element or holders 16. In thisembodiment, the holding element or holders 16 are steel plates shaped inthe manner of a claw, with a cut-out 160 that matches the shape of theload-positioning beam 131, so that the load-positioning beam 131 willrest on the load platform and the upper surface of the lateral beams.Inner holding plates 16′ have a simpler shape, as shown in FIG. 1, andserve to provide additional stability to the overall arrangement. FIG. 1also indicates through-holes 164 in the holding plates 16 and matchingthrough-holes 134 in fins 133 of the load-positioning beams 131.Returning to FIGS. 2A and 2B, the load-positioning beam 131 is securedto the frame 10 by inserting fasteners F through the alignedthrough-holes 134, 164 of the holding plates 16 and fins 133.

The frame 10 and load-positioning beams 131 are now ready to receive thepart adapter 14, which can be lowered into place as shown. To this end,a suitable hoisting or lifting apparatus can be used. The diagram showsa row of downward-pointing bars 143 mounted to the part adapter 14. Eachbar 143 has a number of through-holes 144, so that the part adapter 14can be secured to a load-positioning beam 131 by inserting fasteners Fthrough the aligned through-holes 134, 144 of the bars 143 andload-positioning beam fins 133, as shown on the right-hand side of thediagram.

FIG. 3 shows the inventive transport assembly 1 of FIG. 2A and FIG. 2Bin use during the transport of a nacelle unit 2. The frame 10 has beenplaced in a predetermined position on the load platform 3 of a transportvehicle (not shown). The frame position can have been determined byconsideration of the combined weight of the nacelle unit 2 and all theparts already installed in or on the nacelle unit 2, as indicated in thediagram. The position of the frame 10 is determined in advance to ensurethat the center of gravity of the nacelle unit 2 will be centrallypositioned over the load platform 3. The tower head interface 20 of thenacelle unit 2 engages with the part adapter 14. The entire assembly cannow be safely transported over any distance, and the balanced loaddistribution ensures that stress damage to the nacelle unit 2 and thetransport equipment 1, 3 is avoided.

FIG. 4 shows a second arrangement of the inventive transport assembly 1,using the long load-positioning beam 132, frame unit 10 and adapter 14of FIG. 1. In this setup, a relatively large nacelle unit is to betransported, i.e. the weight and dimensions of the nacelle require theuse of two load platforms. On the left-hand side of the diagram, twolong load-positioning beams 132 are shown in place, spanning two framesunits 10. Each load-positioning beam 132 spans the two frames units 10and is held in place by holding plates 16 and fasteners F as describedabove.

The frames units 10 and load-positioning beams 132 are now ready toreceive the part adapter 14 of a large nacelle unit, which can belowered into place as shown. As described above, the part adapter 14 issecured to the load-positioning beams 132 by inserting fasteners Fthrough aligned through-holes 134, 144 of the bars 143 andload-positioning beam fins 133 as shown in the enlarged detail view onthe right-hand side of the diagram.

FIG. 5 shows the inventive transport assembly 1 of FIG. 4 in use duringthe transport of a large nacelle unit 2. In this case, the nacelle unit2 also comprises an entire nacelle with hub and spinner in place at thefront of the nacelle, and a cooling arrangement and landing platform inplace on top of the nacelle. The combined weight of such a nacelle unit2 can lie in the region of 300-800 metric tons or even more. The frameunits 10 have been placed in predetermined positions on adjacent loadplatforms 3 of a transport vehicle (not shown). The load platforms 3 inthis case will be jointly pulled by a single transport vehicle. The loadplatforms 3 are effectively held in position by the arrangement of frameunits 10 and load-positioning beams 132 of the inventive transportassembly 1. As described above, the frame positions can have beendetermined by consideration of the combined weight of the nacelle unit2, to ensure that the center of gravity of the nacelle unit 2 will becentrally positioned over the load-carrying area defined by the adjacentload platforms 3 and the load-positioning beams 132. The tower headinterface of the nacelle unit 2 is secured to the part adapter 14. Inthis case also, the entire assembly can now be safely transported overany distance, and the balanced load distribution ensures that stressdamage to the nacelle unit 2 and the transport equipment 1, 3 isavoided.

FIG. 6 shows the inventive transport assembly 1 of FIGS. 2A and 2B inuse during the transport of load 2, in this case a tower head unit. Thediagram shows the tower head unit in place over a part adapter 14. Thetower head unit can safely be transported from one location to anotherduring the manufacture of a nacelle unit, for example.

Although the invention has been illustrated and described in greaterdetail with reference to the preferred exemplary embodiment, theinvention is not limited to the examples disclosed, and furthervariations can be inferred by a person skilled in the art, withoutdeparting from the scope of protection of the invention.

For the sake of clarity, it is to be understood that the use of “a” or“an” throughout this application does not exclude a plurality, and“comprising” does not exclude other steps or elements.

1. A transport assembly for securing a load to a load platform during atransport maneuver, comprising: at least one frame unit configured tolie on a load platform of a transport vehicle, wherein the at least oneframe unit comprises at least one transverse beam arranged to extendacross a width of the load platform and held in place by a pair oflateral beams arranged to extend lengthways along sides of the loadplatform; at least one load-positioning beam, wherein the at least oneload-positioning beam is selected from: a) a first load-positioningbeam, wherein the first load-positioning beam is configured to span awidth of a single frame unit of the at least one frame unit; and b) asecond load-positioning beam, wherein the second load-positioning beamis configured to span a width of a pair of adjacent frame units of theat least one frame unit; and a part adapter configured to engage withthe at least one load-positioning beam and to engage with the load. 2.The transport assembly according to claim 1, wherein the at least onetransverse beam is arranged to rest on an upper surface of the loadplatform.
 3. The transport assembly according to claim 1, wherein thefirst load-positioning beam is configured to engage with the partadapter when the part adapter is positioned centrally over the at leastone frame unit, and wherein the second load-positioning beam isconfigured to engage with a part adapter when the part adapter ispositioned centrally over the pair of adjacent frame units of the atleast one frame unit.
 4. The transport assembly according to claim 1,comprising an arrangement of bars mounted to the part adapter and acomplementary arrangement of fins mounted to the at least oneload-positioning beam, wherein the bars and fins comprise matchingthrough-holes for receiving fasteners to form a connection between thepart adapter and the at least one load-positioning beam.
 5. Thetransport assembly according to claim 1, comprising a number of holdersarranged to hold the at least one load-positioning beam in place on theat least one frame unit.
 6. The transport assembly according to claim 5,wherein at least one holder of the number of holders is arranged toextend upward from a respective lateral beam of the at least one frameunit to engage from below with the at least one load-positioning beam.7. The transport assembly according to claim 5, wherein at least oneholder of the number of holders is arranged to extend downward from theat least one load-positioning beam to engage from above with arespective lateral beam of the at least one frame unit.
 8. The transportassembly according to claim 5, wherein at least one holder of the numberof holders is constructed as a plate comprising a rectangular cut-out tofit about the at least one load-positioning beam.
 9. The transportassembly according to claim 8, comprising a matching arrangement ofthrough-holes in the plate and in a complementary arrangement of finsmounted to the at least one load-positioning beam, for receivingfasteners to secure the at least one load-positioning beam to the atleast one frame unit.
 10. The transport assembly according to claim 1,configured to transport a wind turbine nacelle unit with a weight of atleast 200 metric tons.
 11. The transport assembly according to claim 1,wherein the part adapter is configured to connect to a wind turbinetower head interface with a diameter of at least 4 m.
 12. A method ofsecuring a load on a load platform during a transport maneuver,comprising: providing at least one frame unit configured to lie on aload platform of a transport vehicle; providing at least oneload-positioning beam, wherein the at least one load-positioning beam isselected from a) a first load-positioning beam, wherein the firstload-positioning beam is configured to span a width of a single frameunit of the at least one frame unit, and b) a second load-positioningbeam, wherein the second load-positioning beam is configured to span awidth of a pair of adjacent frame units of the at least one frame unit;arranging either a) the single frame unit over the load platform andarranging the first load-positioning beam across the single frame unit,or b) the pair of adjacent frame units over the load platform andarranging the second load-positioning beam across the pair of adjacentframe units; and subsequently engaging a part adapter with the at leastone load-positioning beam; and engaging the load with the part adapter.13. The method according to claim 12, comprising a preliminary step ofdetermining an optimal position for the at least one frame unit on theload platform on the basis of the weight of the load and/or the shape ofthe load.
 14. The method according to claim 13, comprising a preliminarystep of determining an optimal position of a transverse beam and/or theat least one load-positioning beam relative to a lateral beam of theframe unit on the basis of the weight of the load and/or the shape ofthe load.